Magnetic Core Assembly And Manufacturing Process Thereof

Abstract

Optimum magnetic core assembly ( 100 ) and manufacturing process thereof comprising a primary magnetic alloy ( 101 ) and at least one supplementing magnetic alloy ( 102 ), made of a magnetic material ( 90 ) pre-coated with an electrically insulating layer ( 90 C); the optimum open magnetic core assembly ( 100 ) has a pair of ends of a laminated magnetic core ( 110 ), each of the pair of ends of the optimum magnetic core assembly ( 100 ) being one of a co-facing ( 111 ) and a flat ( 113 ), or a co-facing ( 111 ) and a contoured ( 114 ), or a co-planer ( 112 ) and a flat ( 113 ), or a co-planer ( 112 ) and a contoured ( 114 ); a process of producing is one of a wrapping based process ONE ( 30 ) or a stamping based process TWO ( 40 ) followed by a magnetic performance treatment ( 50 ); the optimum magnetic core ( 100 ) is a hybrid core wherein the laminations are grouped and or interlaced laminations ( 70 ).

01 . An optimum open magnetic core assembly ( 100 ) characterized by:
 a primary magnetic alloy ( 101 ) and at least one supplementing magnetic alloy ( 102 ), made of a magnetic material ( 90 ) pre-coated with an electrically insulating layer ( 90 C);   wherein the optimum open magnetic core assembly ( 100 ) is made of a plurality of laminated magnetic core ( 110 );   wherein the optimum magnetic core assembly ( 100 ) has a pair of ends of a laminated magnetic core ( 110 ), each of the pair of ends of the optimum magnetic core assembly ( 100 ) being one of a co-facing ( 111 ) and a flat ( 113 ), or a co-facing ( 111 ) and a contoured ( 114 ), or a co-planer ( 112 ) and a flat ( 113 ), or a co-planer ( 112 ) and a contoured ( 114 ); and   wherein a process of producing the optimum magnetic core assembly ( 100 ) is one of a wrapping based process ONE ( 30 ) or a stamping based process TWO ( 40 ) followed by a magnetic performance treatment ( 50 ),   wherein the process of producing the optimum magnetic core assembly is governed by the pair of ends of the laminated magnetic core,   wherein the process of producing the optimum magnetic core assembly is decided based on a plurality of inputs on application of the optimum magnetic core assembly ( 100 ) and a level ONE of specifications,   wherein the level ONE of specifications includes a magnetic material, a lamination thickness, a hardness, a lamination shape, a shape of pole, and a core dimension.   
     
     
         02 . The optimum open magnetic core assembly ( 100 ) as claimed in  claim 01 , wherein the optimum core assembly ( 100 ) has a stacking factor of 96 to 99%. 
     
     
         03 . The optimum open magnetic core assembly ( 100 ) as claimed in  claim 01 , wherein the magnetic material ( 90 ) has an initial hardness of 420 to 480 HV (on Vickers scale). 
     
     
         04 . The optimum open magnetic core assembly ( 100 ) as claimed in  claim 01 , wherein the electrically insulating layer ( 90 C) flows onto a sheared edge and a sheared surface ( 89 ) of the magnetic material ( 90 ). 
     
     
         05 . The optimum open magnetic core assembly ( 100 ) as claimed in  claim 01 , wherein the process ONE ( 30 ) comprises the steps of:
 a. Entrapping a start edge ( 62 ) of a roll of a sheet of a selected magnetic material ( 90 ) of the primary magnetic alloy ( 101 ), by folding and lockingly engaged with a slot ( 63 ) in a mandrel ( 64 ),   b. Pulling the sheet of the selected magnetic material by a tensile force Ft ( 65 ) while the mandrel ( 64 ) is rotating,   c. Applying a compressive force Fc ( 66 ) intermittently by momentarily stopping the mandrel ( 64 ) in an orthogonal plane ( 67 ),   d. Slitting the sheet on achieving a requisite width ( 68 ) of a thus wound core ( 91 ),   e. Disposing permanently a last edge of the sheet on the wound core ( 91 ),   f. Dismounting the wound core ( 91 ) by sliding the wound core ( 91 ) out of the slot ( 63 ) in the mandrel ( 64 ),   g. Passing the wound core ( 91 ) through a correction fixture ( 31 ),   h. Repeating the above steps with the supplementing magnetic alloy ( 102 ),   i. Inserting interferingly a corrected wound core ( 92 S) of the supplementing magnetic alloy in a corrected wound core ( 92 ) of the primary magnetic alloy to arrive at a hybrid corrected core ( 93 ),   j. Slitting and slicing the hybrid corrected core ( 93 ) to obtain a bare magnetic core assembly ( 94 ),   k. Growing grains of the bare magnetic core assembly ( 94 ),   l. Vacuum impregnating the bare magnetic core assembly ( 94 ),   m. Encasing a treated magnetic core assembly ( 95 ) in a non-magnetic resin or a non-magnetic engineering plastic body.   
     
     
         06 . The optimum open magnetic core assembly ( 100 ) as claimed in  claim 05 , wherein the entrapping the start edge ( 62 ) is by engaging a plurality of orifices ( 71 ), with a plurality of spring-loaded pin ( 72 ) disposed in a second mandrel ( 64 S). 
     
     
         07 . The optimum open magnetic core assembly ( 100 ) as claimed in  claim 05 , wherein the dismounting of the wound core ( 91 ) from the second mandrel ( 64 S) is by pulling back the plurality of spring-loaded pins ( 72 ). 
     
     
         08 . The optimum open magnetic core assembly ( 100 ) as claimed in  claim 05 , wherein the tensile force Ft ( 65 ) is lower than a tensile strength of the sheet of the magnetic material ( 90 ). 
     
     
         09 . The optimum open magnetic core assembly ( 100 ) as claimed in  claim 05 , wherein the corrected wound core ( 92 S) of the supplementing magnetic alloy has an external width ( 81 S) and an external height ( 82 S) tending to be equal to an internal width ( 81 ) and an internal height ( 82 ) of the corrected core ( 92 ) of the primary magnetic alloy. 
     
     
         10 . The optimum open magnetic core assembly ( 100 ) as claimed in  claim 01 , wherein the process TWO ( 40 ) comprises the steps of:
 (i) Producing a required number of primary stampings ( 53 ) of the primary magnetic alloy and a required number of supplementary stampings ( 53 B),   (ii) Stacking the primary stampings ( 53 ) and the supplementary stampings ( 53 B),   (iii) Compressing the primary stampings ( 53 ) and the supplementary stampings ( 53 B) and inseparably attaching to one another through a joining means provided on each stamping, to obtain the bare optimum magnetic core ( 94 S),   (iv) Growing a grains of the bare optimum magnetic core assembly ( 94 S),   (v) Vacuum impregnating the bare optimum magnetic core assembly ( 94 S),   (vi) Encasing a treated optimum magnetic core assembly ( 95 ) in a non-magnetic resin or a non-magnetic engineering plastic body.   
     
     
         11 . The optimum open magnetic core assembly ( 100 ) as claimed in  claim 10 , wherein the joining means is a plurality of partially displaced projections ( 54 ). 
     
     
         12 . The optimum open magnetic core assembly ( 100 ) as claimed in  claim 01 , wherein the plurality of magnetic laminations ( 110 ) are an interlaced laminations ( 70 ) of the primary magnetic alloy ( 101 ) and supplementary magnetic alloy ( 102 ). 
     
     
         13 . The optimum open magnetic core assembly ( 100 ) as claimed in  claim 01 , wherein the plurality of magnetic laminations ( 110 ) are a stacking of the required number of stampings of the primary magnetic alloy ( 101 ) and the supplementing magnetic alloy ( 102 ) in at least a single group of each. 
     
     
         14 . The optimum open magnetic core assembly ( 100 ) as claimed in  claim 05 , wherein the treated magnetic core assembly ( 95 ) is provided with a resin coating ( 58 ), the treated magnetic core assembly ( 95 ) is preheated at 250° C. for 20 min, then immersed in a vibrating resin powder, for a prescribed time depending on a desired thickness of coating and a size of the treated optimum magnetic core.